MAINTENANCE FITTER - MECHANICAL · 2019-01-29 · MAINTENANCE FITTER - MECHANICAL ... Ask following Questions Group Discussion

EINFOLINGUA SERVICES

1 | M a i n t e n a n c e F i t t e r - M e c h a n i c a l ( F a c i l i t a t o r ’ s G u i d e )

MAINTENANCE FITTER - MECHANICAL

(Facilitator’s Guide)

REFERENCE ID: CSC/Q 0901



Introduction to the Facilitator Guide

1. Preface and Purpose of the Guide This guide is designed to help you (the facilitator) to plan and conduct the course. 2. What will I find in the guide? This facilitator’s guide is a comprehensive package that contains:

Presentation scripts and key points to cover

Key points at a glance

Facilitation tips

Sampling of potential questions

Checklist of necessary materials and equipment

3. Program Preparation

Programs require a significant amount of preparation. It is crucial that program facilitators

familiarize themselves with the material they designed or are expected to deliver and have

adequate time to adapt the content to the specific audience.

4. The Role of the Facilitator

Who is a facilitator?

A facilitator is someone who is present to assist a group in reaching its objectives; the group, not

the facilitator, may determine the objectives.

The facilitator’s role:

When adopting the role of a facilitator, the facilitator needs to:

Ensure the mere verbose do not take over and encourage contributions, particularly from

those who may be less confident

Devise non-aggressive, friendly ways to deal with difficult participants

Control conflict by stepping in if necessary to help participants learn to deal with conflict

positively

From time to time get the participants to summarize what has been discussed

Assist ‘weaker’ participants by rephrasing their arguments for them so that these do not

get lost just because they are not forcefully put across

Provide feedback to the group as a whole as to its performance

Provide the information and resources for the group to function effectively

Session Preparation:

A. Questions

What

• What is the subject I have been asked to present on/lead/arrange Why

• Why have they asked me to do it?



• What is the purpose of the session or the training course? • To communicate information and knowledge. • To make a proposition. • To test existing knowledge. • To practice skills. • To inspire and motivate. • The first thing to get clear in your mind is the objectives of the entire course or one

session. When

• What time of day will my session(s) take place? After lunch is known as the graveyard slot; you should therefore consider making it more active than, say, a morning session.

• How long have I got? How

• How am I going to present my subject? • Straight talk • Talk with overheads • Talk with PowerPoint presentation • Talk with video • Give the participants a period in which to discuss aspects of the subject, e.g. by using a

case study. • Combination of any of these. • Am I going to allow questions during the session? • Always leave time at the end for questions and discussion.

Where

• Where is the presentation due to take place? • How do the windows open/air conditioning work? If using PowerPoint or video, how do

we darken the room? • What equipment have they got, e.g. video, computer, projector, overhead projector,

etc.? • Decide on seating arrangements • Are there likely to be any distractions, e.g. loud air-conditioning; things happening

outside the window, etc. • Can I be heard at the back of the room?

Who

• Who are they? How senior/junior are they? • How many will be present? • What is the extent of their existing knowledge of the subject I am going to present? • What will be of interest to them? • What will their attitudes, preconceptions or expectations? • Is there a gender balance within the group? • Could you foresee or expect any kind of dynamics or potential resistant due to group

composition? • What can you glean overall from the participants list and profile without making too

many assumptions?



Icons Used In This Guide

Icon

Description/guidelines

Trainer Led Discussion

Show a slide < Used to denote the slide to be shown>. Even better

paste the image of the slide being discussed.

Show a video

<mention video/clip name>

Evaluate – administer assessment

<mention name and guidelines for assessment>

Narrate/Share astory or valid examples

Share insights or ask participants to share insights about current topic

Distribute Hand-outs

Transition from one subject/topic/objective/story, etc to another

(also could indicate flow)



Derive objective/key point

Materials required

Ask following Questions

Group Discussion

<mention guidelines (number in each group, whether team leader is

required in each group, etc.) and duration>

Play music

< mention file names and duration>

Capture on flipchart and put up in the class to be reference at a later

point during the class or to summarize the learning of the session

Summarize the session/day

Activity – describe activity

Debrief to bring out relevant learning



TOPIC WISE CONTENTS

1 Occupational Health & Safety in Engineering Workshops

12 – 29

2 Fundamental Concepts of Mechanical Engineering

30 – 42

3 Engineering Drawing Basics

43 – 59

4 Fault Diagnostic Techniques & Equipment

60 – 73

5 Performing Mechanical Maintenance Operations

74 – 117

6 Emergencies, Rescue and First-aid Procedures

118 – 195

7 Work Effectively with Others

196 – 228



Table of Contents

Unit - 1 Occupational Health & Safety in Engineering Workshops

Introduction

Job of a Fitter

Employment Opportunities

Layout of the Shop Floor

Occupational Health & Safety

Causes of Workshop Accidents

Safety Precautions at Shop Floor

Safety Guidelines for Fitting Work

Workplace Hazards

Precautionary Measures to be Taken to Prevent from

Hazards

Precautionary Measures to Prevent from Workplace

Hazards

30 Hrs

Unit - 2 Fundamental Concepts of Mechanical Engineering

Introduction

Interchangeability

Limits

Tolerance

Allowance

Fit

Fit - Hole Basis & Shaft Basis System

30 Hrs

Unit - 3 Engineering Drawings Basics

Introduction to Customer Service

The Importance of Good Customer Service

How to Improve your Customer Service Skills

Following Customer-Centric Approach

Building Strong Customer Relationships

Dealing with a Range of Customers and Understand their Needs and Issues

Identify Customer Needs

Reverting to Customer Queries/Complaints

Interacting with Customer Prior to Visit

40 Hrs



Interacting with Customer at their Premises

Suggesting Possible Solutions to Customer

Achieving Productivity and Quality Standards

Importance of Maintaining Clean Surface/Work Area

Unit - 4 Fault Diagnostic Techniques & Equipment

Introduction

Spanners

Pliers

Screw Driver

Fault Diagnostic Techniques & Equipments

Algorithm & Flowcharts

Test Equipment

30 Hrs

Unit - 5 Performing Mechanical Maintenance Operations

Maintenance of Gear Box

Service & Maintenance of Lifting Equipment

Maintenance of Work Holding Devices

Reassemble the Components

Mechanical Assembly – Methods

Service & Maintenance Techniques

Maintenance & its Types

Purpose of Maintenance

Types of Maintenance

Maintenance Schedule

Repair Cycle

Preparation of Schedule

Maintaining Records

Lubrication

Purpose of Lubrication

Lubricants

Types of Lubricant

Properties of Lubricant

Lubricating Devices

Coolant (Cutting Fluid)

Properties of a Good Coolant

Types of Coolants (Cutting Fluid)

128 Hrs



Overall Equipment Effectiveness (OEE)

Regulatory Compliance

Visual Management

5’S’

Benefits of 5’S’

Spirit Level

Overhauling of Machines

Alignment of Machines

Unit - 6 Emergencies, Rescue and First-aid Procedures

Employee Health and Safety

Monitoring Safety Practices

Workplace Safety Tips

Safeguards for Personnel Protection

Personal Protective Equipment (PPE)

Personal Protective Kit

Protective Clothing & Protective (Safety) Gear

Maintenance of PPE

Electrical Testing of Electrical Protective Equipment

Training Required for PPE

How to Determine What PPE must be worn?

Overcoming Staff Reluctance

Consider using the 'Four E’s

Personal Safety

Safety with Hand Tools

Safety with the Machine

Safety in Workshop

Safety with Drilling Machines

Safety with Grinding

Safety with Lathes

Safety with Lifting Loads

First Aid

First Aid Kit

Types of Injury and their Prevention

First-aid Procedures

First Aid Management

How to Apply Different Types of Bandages

Basics of Bandaging

62 Hrs



Bandaging of Minor Wound

Bandaging Serious Wounds

Applying a Strip Bandage

Applying a Wrap/Elastic Bandage

Staging & Housekeeping

Benefits of Good Housekeeping

Preventing Electrical Hazards

Using Electrical Equipment Safely

Preventing Electric Shock on the Job

First Aid for Electric Shock

Safety Measures while Working at Height

Dos and Don’ts of Working at Height

How to Minimise the Consequences of a fall

Identification of Fragile Surfaces

Types of Fires

Prevention of Fire

Extinguishment of Fire

Common Causes of Workplace Fires

How to prevent hot work incidents?

How to prevent flammable liquid and gas incidents?

How to prevent electrical fire incidents?

What to Do in the Event of a Fire – and How to Avoid

One

Fire Extinguisher

Types of Fire Extinguishers

Care & Maintenance of Fire Extinguisher

Fire Sprinkler System

Smoke Detectors

Sounders and Strobes

Alerting Techniques

Safety Signs

Unit - 7 Work effectively with others

Working with Colleagues

Be Polite and Cooperative with Others

Take Opportunities to Enhance the Level of Support

Offered to Colleagues

Address all Requests and Issues within a given

80 Hrs



Timeframe

Delivering Quality Work on Time

Seek Assistance when Difficulties Arise

Ask Questions to Clarify on Given Instructions or to

Understand Responsibilities

Have a Unbiased Attitude with all Contacts, Customers

and other Staff Members

Respect your Colleagues

Communicating about Potential Hazards at Workplace

Handing over the Work and Receiving Feedback

Communication Skills and Etiquettes

What is Communication?

Etiquettes for Face-to-Face Conversation:

Etiquettes for Telephonic Conversation

Non-verbal Communication

Writing Skills

Basic E-Mail Etiquettes

Tips to Write Effective Official and Business Letters

Active Listening

Professional Appearance

Workplace Ethics

Assertiveness

Tips for Effective Verbal and Non-verbal

Communication

Disciplined Behaviors



Unit 1

Occupational Health & Safety in

Engineering Workshops



The Session in Perspective

Unit 1: Occupational Health & Safety in Engineering Workshops

Module Learning Goals

This module covers the overview of occupational health and safety in engineering workshops.

Enabling objectives:

Upon completion of this module, the participant will be able to:

Understand and learn about the role of a fitter

Understand and learn about safety guidelines for fitting work

Identify different types of hazards at workplace

Understand and learn about precautionary measures to be taken to prevent from hazards

Methodology

Trainer Led Discussion, Skill Practice, Individual Reflection, Assessment

Instructions to the Trainees: The students should participate while the trainer

discusses about each topic to make the class more interesting.

Equipment /Tools Required:

Computer, Projector, White Board, Participants Manual, Markers, Flipcharts, Notes,

Handout & PPT

Duration: 30 Hours



Introduction 2 Hrs

The process of Fitting is widely applied to engineering technology which involves machining,

maintenance & assembly operations. The process of fitting involves making /producing the

components as per the client requirements or as per the manufacturing, engineering environment.

Fitting is the process of removing unwanted material with the help of hand tools, from a given

stock for making a component or fitting one in the other to form a mating or fitting pair.

Presently in most of the industries, the work is done using automatic machines which produces the

jobs with good accuracy. But, for certain jobs still there is a need to perform the work by using

hand operations, which is known as fitting. The person who performs the fitting work is known as

fitter.

Fitting & Bench working are just like two faces of the coin. The bench working involves the use of

hand tools like hacksaw, chisel, file, scraper, taps, dies and a variety of making and measuring

instruments for performing various bench working processes like cutting, chipping, scraping,

threading, etc. on metal pieces.

A fitter is supposed to have a well versed knowledge pertaining to use of tools & instruments. The

bench working processes are mostly carried out on a job held in a vice fitted on the fitter’s working

table. But sometimes the use of these processes and hand tools for site works proves quite

effective and useful because of the flexibility and ease they provide in tackling difficult situations,

particularly where power-operated machines may not be used.

Job of a Fitter

The job of a fitter mainly involves preparing, fitting and

assembling metal parts. A fitter needs to be well-versed

and skilled in selection, use and operation of hand tools,

measuring instruments and quality requirements of

finished products.

Laying out the jobs as per product drawings provided,

cutting, sawing, filing, scraping, drilling, reaming,

threading welding, soldering, heat treating are examples

of operations that a skilled fitter should be able to carry

out with high degree of perfection.



Knowledge of various kinds of working materials (e.g. metals) their properties and behaviour is

called for. Acquiring proper safety practices forms an essential part of the skill training

programme.

Employment Opportunities

On successful completion of training, the candidates are likely to have employment opportunities in

following industries:

1) Production & Manufacturing industries

2) Structural fabrication like bridges, roof structures, building & construction

3) Automobile and allied industries

4) Service industries like road transportation and railways

5) Ship building and repair

6) Infrastructure and defense organizations

7) In public sector industries like BHEL, BEML, NTPC, and private industries in India & abroad

8) Self-employment

Show Video: A day in the life of a fitter 2 Hrs

www.youtube.com/watch?v=Zk9NZsbxpPY

Instructions for the facilitator

Ask students to watch the mentioned video and gain knowledge about a day in the life of a

fitter.

Resolve their queries if any.

Show Video: A Fitter On The Job02:00 Hrs

www.youtube.com/watch?v=Tz4aQBnWagA




Ask students to watch the mentioned video and gain knowledge about a fitter on the job.


Layout of the Shop Floor 2 Hrs

A few examples of shop floor layout are given here. It consists of the following set of tools and

equipments:

Tool Boxes

Clamp racks

Drill press

Jet dust collector

Bench

Hand tool wall cabinet

14” band saw

Table saw (Mobile on casters)

Sharpening station





Show Video: Shop Floor Layout 02:00 Hrs

www.youtube.com/watch?v=Vc7gofWMgnw


Ask students to watch the mentioned video and gain knowledge about the shop floor layout.


Show Video: Shop Floor Layout Optimization 02:00 Hrs

www.youtube.com/watch?v=aZRtlXlbyN0


Ask students to watch the mentioned video and gain knowledge about shop floor

optimization.




Occupational Health & Safety 06:00 Hrs

An accident is an unplanned and non-controlled event in which the action or reaction of an object,

substance or person results in personal injury.

Results of Accidents: Accidents result in the following –

Complete loss of equipment and building

Partial loss of equipment or building

Loss of production

Loss of lives of employees

Permanent Disability of the persons due to loss of limbs, eye sight, hearing etc

Temporary disablement due to injuries

Causes of Workshop Accidents

Human Causes: Carelessness and overconfidence

Hand Tools: Use of faulty or improper tools to perform the job

Working Conditions: Slippery floors, poor ventilation, poor lighting and inadequate space

Machines: Unguarded machinery, poor maintenance, improper adjustments, etc

Materials: Storage of inflammable materials in unsecured places, sharp and pointed tools and jobs

An Improper Position or Posture or an uncomfortable dress can also cause accidents at workplace

Safety Precautions at Shop Floor

The following safety precautions should be taken care of while using hand tools and equipments.

These safety precautions are most important for prevention of accidents:

1. Maintain a discipline at shop floor

2. Ensure the teeth of hacksaw are sharp and along the forward position

3. While handling a chisel, keep its directions away from other persons working on the shop

floor

4. Check the measuring instruments such as Vernier calipers & micrometer for errors, before

it is used for length measurements



5. When files are under forward cut, apply force along the forward stroke rather than

backward & vice versa

6. Do not wear any neck tie, jewelry, rings, and watches while working in the shop floor

7. Clean the spills caused by oil & grease on the floor to prevent from slipping

8. Ensure that the hack saw blade is fitted to the pins properly

9. Always use appropriate Personal Protective Equipment (PPE)

Safety Guidelines for Fitting Work

Safety is very important while carrying out fitting work. It is imperative that safe working practices

are observed at all times. Failure to observe safety rules will result in that individual losing the

privilege to work in fitting shop.

All tools are dangerous if used improperly or carelessly. Working safely is the first thing the fitter

should learn because the safe way is the only correct way. A person learning to operate machine

tools must first learn the safety regulations and precautions for each tool or machine. Most

accidents are caused by not following prescribed procedures.

1. Eye Protection

Using eye protection in the machine shop is the most important

safety rule for all. Metal chips and shavings can fly at great

speeds and distances and cause serious eye injury.

Safety glasses must be worn when working with hand cutting

tools, since most hand cutting tools are made of hardened

steel and can break or shatter when used improperly.



There are many different types of safety glasses available in the supply system; however, the ones

that offer the best protection are the safety glasses with side shields. Safety goggles should be

worn over prescription glasses as well.

2. Foot Protection

The floor in a machine shop is often covered with razor-sharp metal

chips, and heavy stock may be dropped on the feet. Therefore,

safety shoes or a solid leather shoe must be worn at all times. Safety

shoes have a steel plate located over the toe and are designed to

resist impact. Some safety shoes also have an in-step guard.

3. Grinding Dust and Hazardous Fumes

Grinding dust from abrasive wheels is made up of extremely

fine particles of the metal and the wheel. Some grinding

machines are equipped with a vacuum dust collector.

When operating a grinder without a vacuum, wear an approved

respirator to avoid inhaling the dust.

Whenever possible, use coolant when grinding. This will aid in

dust control. Grinding dust can be very dangerous to your

health, especially beryllium or parts used in nuclear systems. These materials require careful

control of grinding dust.

4. Electrical safety

The machine operator is mostly concerned with the on/off switch on the machine. However, if

adjustments or repairs have to be made, the power source should be disconnected. If the machine

tool is wired permanently, the circuit breaker should be switched off and tagged with an

appropriate warning statement.

Most often the power source will not be disconnected for routine adjustment such as changing

machine speeds. However, if a speed change involves a belt change, make sure that no other



person is likely to turn on the machine while the operator’s hands are in contact with belts and

pulleys.

Hazards & Type of PPE

PPE Protection Hazard Prevention Area of Protection

Eye Protection Chemical or metal splash, dust, projectiles, gas and vapour, radiation

Wear safety glasses

Near welding machine

Hearing Protection

Noise Wear ear plugs In noisy area

Head Protection Risk of Head bumping, Falling or flying objects

Wear industrial safety helmets

Material handling and storage area



Hand Protection Abrasion,

temperature

extremes, cuts

and punctures,

impact,

chemicals,

electric shock,

radiation,

vibration, and

prolonged

immersion in

water

Wear safety

gloves

Near cleaning

station and

assembling area,

as well as during

welding

operation

Respiratory

protection

Oxygen-deficient

atmospheres,

dusts, gases and

vapours

Wear suitable

respirators

approved as

per IS

specifications;

shall be worn

wherever

necessary

Near welding

machine

Whole body

protection

Heat, chemical or

metal splash,

spray from

pressure leaks or

spray guns,

contaminated

dust, impact or

penetration,

excessive wear or

entanglement of

own clothing

Wear aprons Welding area

Foot Protection Chemical splash,

work in wet areas

Wear safety

shoes

Near cleaning

and welding area



Workplace Hazards

Hazards are the conditions that cause threat to life of human beings and animals in the

surroundings. Hazards may cause serious threats such as nuclear fallout, release of poisonous gases

to atmosphere, spills of oils or grease that leads to slip & falls or fire accidents. Hazards may lead

to serious health issues.

There are mainly three types of hazards:

1) Chemical hazard

2) Physical hazard

3) Ergonomic hazard

Chemical Hazards

The Entry of foreign bodies into a human body is termed as chemical hazards. The chemicals enter

into human body in the following ways:

Inhalation – This is the most common way through which chemicals enter into human body.

When a person respires, the chemicals enter the worker’s body through the process of

respiration.

Ingestion – It is a process in which chemicals are swallowed through eating, drinking etc.



Absorption – It is a process in which chemicals enters into the body through skin & eyes.

Physical Hazards

There are of different types of physical hazards that are hazardous to workers:

i. Noise

ii. Vibration

iii. Temperature Extremes

Noise: When working on machine, if workers are exposed to dangerous noise levels, it can cause a

temporary loss of hearing. The some of the factors which majorly affect the workers are listed out

here:

o When two or more machines producing high sound are operated simultaneously

o Enclosed or partially enclosed spaces

o If a machine is not properly maintained or malfunctioned and produces high noise

levels, when operated

Vibration: While working with large equipments such as drillers, air mallets, pile drivers, tractors,

bulldozers, earth-moving equipment etc., hand-arm vibration usually occurs such as while using

power tools, like pneumatic drills, grinders, etc.

Temperature Extremes – A transformation in body temperature due to risky work environmental

conditions could incorporate stress or illness from heat or cold. If not treated in time, both heat

and cold stress/illness can develop into life-threatening situations.

Heat illnesses causes and injuries: Substantial amount of work in very high temperatures could

lead to muscle cramps, dehydration and unconsciousness. A few symptoms of heat illnesses are as

follows:



o Heat rash

o Fainting

o Heat cramps

o Heat exhaustion

o Heat stroke

o Wearing resistant protective clothing when doing heavy work.

Cold illnesses causes and injuries: A cold temperature majorly causes tiredness, breathing

difficulties and lack of consciousness (hypothermia). A few symptoms of heat illnesses are as

follows:

o Frost nip

o Immersion injury (trench foot)

o Frost bite

o Hypothermia

Ergonomic Hazards

These hazards lead to aching & disabling injuries mainly in muscles and joints. These injuries are

due to following factors:

Repeating chores more than twice

Wrong way of holding a tool, wrong body language (gestures or movements) while working

Lifting heavy weight tools, regular lifting, or wrong method of lifting

Using unnecessary force

Using improperly maintained tools

Using wrong tools for the job

Hand-intensive work

The Ergonomic hazards also lead to musculoskeletal disorders (MSDs) and injuries.

Following are the correct lifting procedures that must be followed at work to avoid Ergonomic

hazards:

Chin tucked in

Comfortably straight back

Leaning slightly forward

Arms close to body

Secure grip

Bent knees

Proper foot position



Common hazards that can lead to an accident:

Slip & fall at the work place due to spill of liquids, oils, water at the floors. To prevent

this, non-slip floor surfaces & fatigue mats must be provided at the shop floor.

Spills of Chemicals

Use of faulty, defective & improperly maintained equipment to perform some operations

leads to accidents. A proper maintenance of equipments is recommended.

Lifting heavy objects manually leads to muscle tension & spinal injuries.

Improper store of chemicals & some dangerous substances leads to fire hazards & in few

cases it leads to explosions also. This can be prevented by make use of fire extinguisher.



Worn out hoses:

Damaged power tools:

Precautionary Measures to Prevent from Workplace Hazards

Wear an appropriate PPE.

Ensure that all tools, equipment’s, extension leads are in safe and usable conditions.

Ensure the machine and its tools are secured at all times. Also, check the work area is kept

free from any hazards.

Carry out regular maintenance of tools & equipments.



Show Video: Shop Floor Safety 2 Hrs

www.youtube.com/watch?v=5LD5-r3rCtY


Ask students to watch the mentioned video and gain knowledge about shop floor safety.


Show Video: 10 Commandments of Workplace Safety 2 Hrs

www.youtube.com/watch?v=3C6js5JtCIQ


Ask students to watch the mentioned video and gain knowledge about 10 commandments of

workplace safety.


Showcase the various safety tools and explain their usage. 4 Hrs

Practice Session: 2 Hrs



Class Assignment: Ask the participants to answer the following questions. 2 Hrs

Describe role and responsibilities of a fitter.

What are the causes of workshop accidents?

What are the safety precautions to ensure health & safety for workers in fitting work?

What are the types of workplace hazards?

Describe the precautionary measures to be taken to prevent from various workplace

hazards.

Discuss in class - What is the learning from this module/unit?

Summarize the Lesson

Ask Questions/Solve the Exercise

Documents

MAINTENANCE FITTER - MECHANICAL · 2019-01-29 · MAINTENANCE FITTER - MECHANICAL ... Ask following Questions Group Discussion